Wall building unit and structure incorporating same



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April 15,-194'1- v J. WHITENA CK WALL BUILDING UNIT AND STRUCTURE --IHCORPQRATING SAME Filed NOV. 8, 1939 4 Sheets-Sheet 1 kdlzfl M3. ZZZ? ygweeb' 7 April 15, 1941- J. B. WHITENACK WALL BUILDING UNIT AND,;$TRUCTURE INCORPOBATING SAME Filed Nov. 8, 1959 4 Sheets-Sheet 2 mill] April 15, 1941. J. B. WHITENAC K 2,238,355

WALL aurwxueuurr AND smuc'runs luconronume suit,

Filed Nov. 8, 1939. 4 Sheets-Sheet 3 April .15, 1941- J. B. WHITENACK WALL BUILDING UNIT AND STRUCTURE INCOlilORATING SAIE 4 Sheets-Sheet 4 Filed NOV. 8, 1939 Patented Apr. 15, 1941 UNITED STATES PATENT OFFICE WALL BUILDING UNIT AND STRUCTURE INCORPORA'I'ING SAME James B. Whitenack, Chicago, Ill.

Application November 8, 1939, Serial No. 303,344

6 Claims.

My invention contemplates and has for its object to provide, building units of novel and sturdy construction which are of very great strength in relation to weight, and which may easily, expeditiously and satisfactorily be assembled with similar units, in the economical erection of composite walls possessing shock, vibration, moisture and vermin resisting qualities which are highly desirable in many kinds of stationary and mobile structures.

Generaly speaking, it may be said that a building unit of the kind contemplated by the present invention consists of a plurality of metal members of novel configuration assembled in novel and mutually sustaining relationship, in an open work frame admirably suitable for the reception and subsequent protection of an initially moldable non-metallic filler; and that such unit may have its several metallic components strongly held in properly fabricated relationship, without the use of bolts, rivets, or tie rods, or other mechanical fastenings, by performing a minimum (e. g, two) of simple welding operations.

These and other features of my invention will appear from the following description and apended drawings, wherein:

Fig. 1 is an elevational view of my invention, as applied to wall structure, with some of the cementitious filler broken away in order to show more structural detail;

Fig. 2 is a top plan view thereof;

Fig. 3 is a side view thereof;

Fig. 4 is a perspective of one of my filler bars;

Fig. 5 is an enlarged elevational view of my invention, similar to Fig. 1, but with the horizontal and vertical mid-sections broken away in order to illustrate chiefly the four corners of the structure;

Fig. 6 is a sectional view taken on the line B6 of Fig. 5;

Fig. 7 is an exploded perspective of the frame members of one of my panel units;

Figs. 8, 9 and 10 are sectional views taken on the lines 88, 99 and l0l0 of Fig. 5;

Fi 11 is a perspective view of a corner of a wall structure according to my invention, taken along the line H-ll of Fig. 5, and showing how the panel frame members abut and are welded;

Fig. 12 illustrates my invention as applied on a large scale as a wall structure;

Figs. 13 and 14 are sectional views taken on the lines 43-43 and l4l4 of Fig. 12;

Fig. 15 illustrates my invention applied as sheathing for freight cars;

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Fi 16 is a plan section taken alongthe lines lG-li of Fig. 15;

Fig. 1'7 is a greatly enlarged detailed sectional view taken along the lines l'l-l'l of Fig. 15;

Fig. 18 illustrates how'the comers of four panel units, according to my invention, come together and interlock when built up into a wall structure similar to Fig. 12; and

Fig. 19 is a sectional perspective taken alon the lines I9-l9 of Fig. 15.

In all of the figures, like numerals refer to similar parts.

I have endeavored to produce a logical wall structure composed entirely of various progressively larger standard units. The sinuous metal channel bars I depicted in Fig. 4 are the basic units of my novel system of building construction. Such bars may be fabricated from rolled or pressed channel irons of any desired crosssectional configuration. In practice, I have found it expedient to employ bars having flat channel vertices 3, and flat lateral flanges 5. The flat surfaces 3 and 5 are desirable because the bars I are arranged in mutually self-supporting stacked relationship and will form a stronger and more secure structure if flat surfaces are in mutual contact than when relatively sharp vertices rest upon each other, or when a sharp vertex rests upon a flat surface. The flat vertex surfaces also contribute to the lateral rigidity of the individual bars and of the composite struc ture of which they form a. part. It is to be noted from Fig. 4 that the bars have two different sets of vertices, namely, the single vertices l l which comprise the flat surface of the flat channel vertices 3, and the double vertices 9 formed of portions of the fiat lower horizontal flanges 5.

The next larger unit of my wall structure is a panel unit Ill comprising a large number of sinuous bars l 01' equal length stacked one upon the other with their like vertices in contact. By this I mean that the single vertices l of one bar are in contact with the vertices l of the adjacent bar, and the double vertices 9 of that adjacent bar are in contact with the double vertices 9 of the next adjacent bar (Figs. 1 and 5). A complete panel unit [0 comprises a large number of bars I stacked in mutually self-supporting relationship as depicted in Fig. 1 and securely held against relative longitudinal movement by a metal frame comprising two channel members II and two ribbed members l3.

Fig. 5 depicts a greatly enlarged elevation, similar to Fig. 1, of one of my panel units I 0. To conserve space. the vertical and horizontal median sections have been broken away, leaving only representative corner areas of the panel unit. The left portion of Fig. 5 illustrates the contact between sets of single vertices 'l in mutual self-sustaining contact, and contact between sets of double vertices I in full elevation. At the right side of Fig. 5 the arrangement of the bars has been illustrated in section in order more clearly to bring out the relationship of the various vertices. I wish to stress that my invention does not require interlocking of the channel vertices to prevent relative lateral motion of the bars, as in some of the prior art patents. All of the vertices are flat and their mutual contact is not such as to prevent relative longitudinal or flat lateral movement. Relative movement of the bars is avoided by the use of an enclosing metal frame defining the limits of each panel structure, and rigidly confining the sinuous bars I.

Fig. 12, it is often desirable, although not necessary, to provide means for securely anchoring the lower edge of the bottom panel member to the floor, to prevent movement of the wall structure; and similarly to prevent lateral movement An additional object of the frame surrounding each unitary panel is to permit the interlocking assembly of a plurality of such panels into a composite wall structure. For this reason the frame members It at the lower and right-hand sides of each panel (Fig. 7) are channel irons whose channel groove i2 is adapted to receive the outer ribs ll of the rib members i3 in interlocking relationship. At the same time the inner rib l5 of ribbed bars l3, as well as the vertices of the channel members ll, serve to abut upon and to confine the vertices I and 9, respectively, of the lower and upper bars of the pile of sinuous bars I of the channel structure as well as the notched ends of each of the bars abutting upon the sides of the frame.

The upper right-hand corner of one of my panel units, as depicted in Fig. 11, is formed by the junction of the upper ribbed bar l3 and the right-hand channel bar H. In order to permit the interlocking of the several adjacent panel units, it is necessary to remove excess metal from the end of the ribbed member, as at H, in order to provide a continuation of the channel l2 of member 10. That may conveniently be accomplished after the corner l9, formed by the bars I0 and I3, has securely been welded or soldered.

After a rigid composite metallic panel unit has been built up, as described, a, solid, impervious, rigid, flat panel may be produced by filling the frame with a plastic filler ll of fiber, asbestos, concrete, asphalt, or other similar ceramic or organic plastic compositions. The appearance of a, finished panel unit is depicted in Fig. 1, wherein may be seen the edges of the flanges 5 which are flush with the surface of the plastic filler. They are, nevertheless, discernible, unless completely covered over by a layer of filler composition, which is not usually preferable, be-

cause a unique advantage of applicants structure lies in the protection given to the cementitious filler H by the exposed edges of the flanges 5, thereby preventing cracking and chipping of the filler when the panel units are subject to hard knocks from heavy movable objects.

Because ofthe complementary relationship of the frame members I0 and I3 surrounding each panel unit, alarge number of the panel units may be placed in adjacent horizontal and vertical positions to form a composite wall, as depicted in Fig. 12. The external ribs of the ribbed frame members l3 cooperate with the grooves of the channel members H as shown in of the upper edge of the upper panel units. This may readily be done, as shown in F8. 13, by engaging the lower channel members ll of the bottom tier of panels I by securing the flat flanges of the lower channel members 24 to the floor 2| by means of screws 25, and by confining the upper ribbed members IQ of the upper tier of panel units l0 against an angle iron bracket 21 by means of a cover strip 28 removably fastened thereto. Before the cover strip 28 is applied, the

composite wall structure may temporarily be securely wedged between the floor 2| and ceiling 22 by means of a plurality of small wedges 29 applied between the central rib of ribbed bar l3 and the angle iron 21.

Fig. illustrates my invention as applied for use as a sheathing or lining for freight cars. A plurality of unitary panels I! are applied to the interior walls 3| of the car 30 in horizontally adjacent edge interlocking relationship. The several panel units ID are securely attached to the sides 3! and ends 32 of the box car 30, preferably by means of watertight lock nut bolts 35 passing through the hard cementitious filler ll of the panel units l0 and the pressed steel walls of the car. The heads 36 of the bolts 35 may be countersunk into the cementitious filler ll, or they may be left flush as in Fig. 17, if they are rounded.

In order to provide means whereto may be nailed the various crates and packing means customarily employed for transporting goods, and which must be securely fastened to the freight car in order to avoid damage to the goods caused by the packages being tossed around in the moving car, I provide a wooden tongue and grooved nailing strip running along the top of the panel units I0 and interlocking with the edges thereof. The nailing strip 40 may be secured to the wall 30 of the car by means of round head bolts 4!. Additional such strips 40 may be placed one above the other in interlocking position, or a second tier of panels 10 may be placed above the nailing strip. The nailing strips are also useful for fastening wooden cross-brads to which may be secured the various crates transported in the car.

I claim:

- 1. A wall building unit comprising a rectangular metallic frame surrounding a hardened plastics panel, one vertical and one horizontal member of said frame bearing a central external longitudinal rib, the other two members of said frame being provided with a central external longitudinal channel adapted to receive and interlock with the ribs of similar adjacent building units, said panel containing numerous metallic reinforcing bars, lending structural strength to the panel unit, the edges of said reinforcing bars being flush with the surface of saidflller and protecting the same against cracking and chipping resulting from contact of the unit with heavy movable extraneous objects.

2. A wall building unit comprising a rectangular metallic frame surrounding a hardened plastics panel containing a plurality of sinuous reinforcing bars of channeled cross-section with flanges extending outwardly on either side thereof, lending structural strength to the panel unit, the flange edges ofsaid reinforcing bars being flush with the surface of said panel and protecting the same against cracking and chipping resulting from contact of the unit with heavy movable extraneous objects.

3. A building unit comprising a metallic frame and a plurality of channeled bars sinuously bent in a plane transversely to the open side of their versely to the open side of their channels, said bars being assembled within said frame in alternately reversed relation with the vertices of one bar in contact with the vertices of a second adjacent bar on one side thereof, and with the bases of said bar in contact with the bases of a third adjacent bar on the other side thereof, the ends of said bars being formed to have interfltting engagement with the ribs on said frame members.

.5. A building unit comprising a metallic frame,

a plurality of channeled bars sinuously bent in a plane transversely to the open side of their channels, said bars being assembled within, said frame and rigidly secured thereto, said bars being positioned in alternately reversed relation, with the vertices of one bar in contact with the vertices of a second adjacent bar on one side thereof and with the bases of said bar in contact with the bases of athird adjacent bar on the other side thereof, said bars having each an outwardly extending flange on each side, of the channel thereof.

6. A building unit comprising a metallic frame and a plurality of sinuously bent channeled bars assembled within said frame in alternately reversed relation, one side member of said frame comprising a straight channeled bar with the open side of the channel thereof outwardly disposed with respect to said frame. an opposite side member of said frame comprising a bar having a rib outwardly projecting with respect to said frame and a similar rib inwardly projecting with respect to said frame, each of said ribs being shaped to enter a channel similar to that of the first frame side member, the ends of said sinuously bent channeled bars being formed to have interfltting engagement with said side frame members.

JAMES B. WHI'I'ENACK. 

